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I also own a 2003 Jetta Wagon with a 5 speed. I was thinking about putting the transmission from it into the Sedan, and putting a 6 speed in the Wagon. Essentially a three way swap.
Anyone done anything like this before? Any special considerations I might have to make to make all of this work?
Actually I did something similar a while back. I put a 6 speed in a 5 speed wagon and sold the 5 speed bits to a friend with an auto wagon. Really, you are doing 2 swaps. I would put the 6 speed (just to make sure, it is a TDI 6 speed, correct?) in the wagon first. You will need all the correct 6 speed bits, axles, trans mount, flywheel & clutch, etc. You will use all the removed 5 speed pieces when you convert the auto. I would remove the 5 speed power steering line from the wagon and use it in the auto swap. Some have bent the auto PS line to fit the 6 speed, but I was never happy with mine. I took the auto PS line and had a local hydraulic hose place install a rubber line in the center. That way you can route it as you like.
Here is a thread I did on my car, if you look at post 34 you will see the PS line. I might also suggest swapping the 5 speed clutch line with the other bits and
getting or making a new hose for the 6 speed without the accumulator.
You can use the shifter and cables from the 5 speed on the 6 speed, although it may be a good time to
replace the shifter bushings. Once the 6 speed is in, you should have a complete 5 speed swap kit, less the clutch pedal, shifter and cables, etc. You can easily source those from a salvage yard as gasser parts are the same. With the 6 speed in the wagon, I would swap the 11mm auto injection pump as well unless you already have one. Of course it's even nicer with a turbo, tune, injectors, exhaust........
